16-1

ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM . . . . . . . . . . . . . . . . 2

IGNITION SYSTEM . . . . . . . . . . . . . . . . . 25

GENERAL INFORMATION . . . . . . . . . . . . . . . . 2

GENERAL INFORMATION . . . . . . . . . . . . . . 25

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 3

SERVICE SPECIFICATIONS . . . . . . . . . . . . 26

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 3

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 26

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 4

Ignition Coil (With Built-in Power Transistor)

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Alternator Output Line Voltage Drop Test . . . . 4

Spark Plug Check and Cleaning . . . . . . . . . . . 27

Output Current Test . . . . . . . . . . . . . . . . . . . . . . . 5

Camshaft Position Sensor Check

Regulated Voltage Test . . . . . . . . . . . . . . . . . . . . 7

Crank Angle Sensor Check . . . . . . . . . . . . . . . 28

Waveform Check Using An Analyzer . . . . . . . . 9

Detonation Sensor Check . . . . . . . . . . . . . . . . . 28

Alternator Relay Continuity Check . . . . . . . . . 10

. . . . . . . . . 28

IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . 29

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CRANK ANGLE SENSOR . . . . . . . . . . . . . . 29

STARTING SYSTEM . . . . . . . . . . . . . . . . 17
GENERAL INFORMATION . . . . . . . . . . . . . . 17
SERVICE SPECIFICATIONS . . . . . . . . . . . . 17
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . 18

CAMSHAFT POSITION SENSOR . . . . . . . 30

DETONATION SENSOR . . . . . . . . . . . . . . . . 31

16-2

ENGINE ELECTRICAL - Charging System

CHARGING SYSTEM
GENERAL INFORMATION
The charging system uses the alternator output
to keep the battery charged at a constant level
under various electrical loads.

Voltage

OPERATION

Approx. 14.4 V

Rotation of the excited field coil generates AC voltage in

the stator.
This alternating current is rectified through diodes to DC
voltage having a waveform shown in the illustration at left.
The average output voltage fluctuates slightly with the
alternator load condition.

Time

When the ignition switch is turned on, current flows

in the field coil and initial excitation of the field
coil occurs.
When the stator coil begins to generate power after
the engine is started, the field coil is excited by
the output current of the stator coil.
The alternator output voltage rises as the field
current increases and it falls as the field current
decreases. When the battery voltage (alternator
S terminal voltage) reaches a regulated voltage

of approx. 14.4 V, the field current is cut off. When

the battery voltage drops below the regulated
voltage, the voltage regulator regulates the output
voltage to a constant level by controlling the field
current.
In addition, when the field current is constant, the
alternator output voltage rises as the engine speed
increases.

SYSTEM DIAGRAM
<4G9>

Stator coil

B
Engine-ECU

Field coil
Voltage
regulator

G
S
L
FR

+
Ignition
Charging switch
warning lamp

Battery

16-3

ENGINE ELECTRICAL - Charging System

<4G6>

B
Stator coil
Engine-ECU

Field coil

G
S
L
FR

Voltage
regulator

+
Ignition
switch

Charging
warning lamp

Battery

ALTERNATOR SPECIFICATIONS
Items

4G9

4G6

Type

Battery voltage sensing

Battery voltage sensing

Rated output V/A

12/85 <Except cold climate zone>

12/100 <Cold climate zone>

12/100

Voltage regulator

Electronic built-in type

Electronic built-in type

SERVICE SPECIFICATIONS
Items

Standard value

Limit

Alternator output line voltage drop (at 30A) V

max. 0.3

Regulated voltage ambient

temp. at voltage regulator V

- 20_C

14.2 - 15.4

20_C

13.9 - 14.9

60_C

13.4 - 14.6

80_C

13.1 - 14.5

Output current

70% of normal output current

Rotor coil resistance W

Approx. 2 - 5

SPECIAL TOOL
Tool

Number

Name

Use

MB991519

Alternator test
harness

Checking the alternator (S terminal voltage)

16-4

ENGINE ELECTRICAL - Charging System

ON-VEHICLE SERVICE
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST

+
Alternator

Terminal B

Ammeter

Voltmeter

This test determines whether the wiring from the

alternator B terminal to the battery (+) terminal
(including the fusible line) is in a good condition
or not.
1. Always be sure to check the following before
the test.
D Alternator installation
D Alternator drive belt tension
D Fusible link
D Abnormal noise from the alternator while
the engine is running
2. Turn the ignition switch off.
3. Disconnect the negative battery cable.
4. Disconnect the alternator output wire from the
alternator B terminal and connect a DC test
ammeter with a range of 0 - 100 A in series
between the B terminal and the disconnected

Battery

output wire. (Connect the (+) lead of the

ammeter to the B terminal, and then connect
the ( - ) lead of the ammeter to the disconnected
output wire.)
NOTE
An inductive-type ammeter which enables
measurements
to
be
taken
without
disconnecting the alternator output wire should
be recommended. Using this equipment will
lessen the possibility of a voltage drop caused
by a loose B terminal connection.
5. Connect a digital-type voltmeter between the
alternator B terminal and the battery (+)
terminal. (Connect the (+) lead of the voltmeter
to the B terminal and the connect the ( - ) lead
of the voltmeter to the battery (+) cable.)

16-5

ENGINE ELECTRICAL - Charging System

6.
7.
8.
9.
10.

Reconnect the negative battery cable.

Connect a tachometer or the MUT-II.
Leave the hood open.
Start the engine.
With the engine running at 2,500 r/min, turn
the headlamps and other lamps on and off
to adjust the alternator load so that the value
displayed on the ammeter is slightly above 30
A.
Adjust the engine speed by gradually
decreasing it until the value displayed on the
ammeter is 30 A. Take a reading of the value
displayed on the voltmeter at this time.
Limit: max. 0.3 V
NOTE
When the alternator output is high and the value
displayed on the ammeter does not decrease
until 30 A, set the value to 40 A. Read the
value displayed on the voltmeter at this time.
When the value range is 40 A, the limit is max.
0.4 V.

11. If the value displayed on the voltmeter is above

the limit value, there is probably a malfunction
in the alternator output wire, so check the wiring
between the alternator B terminal and the
battery (+) terminal (including fusible link).
If a terminal is not sufficiently tight or if the
harness has become discolored due to
overheating, repair and then test again.
12. After the test, run the engine at idle.
13. Turn off all lamps and the ignition switch.
14. Remove the tachometer or the MUT-II.
15. Disconnect the negative battery cable.
16. Disconnect the ammeter and voltmeter.
17. Connect the alternator output wire to the
alternator B terminal.
18. Connect the negative battery cable.

OUTPUT CURRENT TEST

Load
Voltmeter
Ammeter
Charging warning lamp
Ignition switch
Alternator relay

FR
L
S
G

Battery
Engine
-ECU

Alternator

16-6

ENGINE ELECTRICAL - Charging System

This test determines whether the alternator output

current is normal.
1. Before the test, always be sure to check the
following.
D Alternator installation
D Battery
NOTE
The battery should be slightly discharged.
The load needed by a fully-charged battery
is insufficient for an accurate test.
D Alternator drive belt tension
D Fusible link
D Abnormal noise from the alternator while
the engine is running.
2. Turn the ignition switch off.
3. Disconnect the negative battery cable.
4. Disconnect the alternator output wire from the
alternator B terminal. Connect a DC test
ammeter with a range of 0 - 100 A in series
between the B terminal and the disconnected
output wire. (Connect the (+) lead of the
ammeter to the B terminal. Connect the ( - )
lead of the ammeter to the disconnected output
wire.)

10. Turn the light switch on to turn on headlamps

and then start the engine.
11. Immediately after setting the headlamps to high
beam and turning the heater blower switch to
the high revolution position, increase the engine
speed to 2,500 r/min and read the maximum
current output value displayed on the ammeter.
Limit: 70% of normal current output

Caution
Never use clips but tighten bolts and nuts
to connect the line. Otherwise loose
connections (e.g. using clips) will lead to
a serious accident because of high current.
NOTE
An inductive-type ammeter which enables
measurements
to
be
taken
without
disconnecting the alternator output wire should
be recommended.
5. Connect a voltmeter with a range of 0 - 20 V
between the alternator B terminal and the
earth. (Connect the (+) lead of the voltmeter
to the B terminal, and then connect the ( - )
lead of the voltmeter to the earth.)
6. Connect the negative battery cable.
7. Connect a tachometer or the MUT-II.
8. Leave the hood open.
9. Check that the reading on the voltmeter is equal
to the battery voltage.
NOTE
If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator B terminal and the battery (+)
terminal.

12.

13.
14.
15.
16.
17.
18.
19.

NOTE
D For the nominal current output, refer to the
Alternator Specifications.
D Because the current from the battery will
soon drop after the engine is started, the
above step should be carried out as quickly
as possible in order to obtain the maximum
current output value.
D The current output value will depend on
the electrical load and the temperature of
the alternator body.
D If the electrical load is small while testing,
the specified level of current may not be
output even though the alternator is normal.
In such cases, increase the electrical load
by leaving the headlamps turned on for
some time to discharge the battery or by
using the lighting system in another vehicle,
and then test again.
D The specified level of current also may not
be output if the temperature of the alternator
body or the ambient temperature is too
high. In such cases, cool the alternator and
then test again.
The reading on the ammeter should be above
the limit value. If the reading is below the limit
value and the alternator output wire is normal,
remove the alternator from the engine and
check the alternator.
Run the engine at idle after the test.
Turn the ignition switch off.
Remove the tachometer or the MUT-II.
Disconnect the negative battery cable.
Disconnect the ammeter and voltmeter.
Connect the alternator output wire to the
alternator B terminal.
Connect the negative battery cable.

16-7

ENGINE ELECTRICAL - Charging System

REGULATED VOLTAGE TEST
Ignition
switch

Load

Charging warning
lamp

MB991519

Alternator
FR
L
S

Alternator relay

B
Yellow

EngineECU

Battery

Ammeter
Voltmeter

This test determines whether the voltage regulator

is correctly controlling the alternator output voltage.
1. Always be sure to check the following before
the test.
D Alternator installation
D Check that the battery installed in the
vehicle is fully charged.
D Alternator drive belt tension
D Fusible link
D Abnormal noise from the alternator while
the engine is running
2. Turn the ignition switch off.
3. Disconnect the negative battery cable.
4. Use the special tool (Alternator test harness:
MB991519) to connect a digital voltmeter
between the alternator S terminal and earth.
(Connect the (+) lead of the voltmeter to the
S terminal, and then connect the (-) lead of
the voltmeter to a secure earth or to the battery
(-) terminal.)
5. Disconnect the alternator output wire from the
alternator B terminal.

6. Connect a DC test ammeter with a range of

0 - 100 A in series between the B terminal
and the disconnected output wire. (Connect
the (+) lead of the ammeter to the B terminal.
Connect the ( - ) lead of the ammeter to the
disconnected output wire.)
7. Reconnect the negative battery cable.
8. Connect a tachometer or the MUT-II.
9. Turn the ignition switch to the ON position and
check that the reading on the voltmeter is equal
to the battery voltage.
NOTE
If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator S terminal and the battery (+)
terminal.
10.
11.
12.
13.

Turn all lamps and accessories off.

Start the engine.
Increase the engine speed to 2,500 r/min.
Read the value displayed on the voltmeter when
the alternator output current alternator
becomes 10 A or less.

16-8

ENGINE ELECTRICAL - Charging System

14. If the voltage reading conforms to the value

in the voltage regulation, then the voltage
regulator is operating normally.
If the voltage is not within the standard value,
there is a malfunction of the voltage regulator
or of the alternator.
15. After the test, lower the engine speed to the
idle speed.
16. Turn the ignition switch off.

17.
18.
19.
20.

Remove the tachometer or the MUT-II.

Disconnect the negative battery cable.
Disconnect the ammeter and voltmeter.
Connect the alternator output wire to the
alternator B terminal.
21. Remove the special tool, and return the
connector to the original condition.
22. Connect the negative battery cable.

Voltage Regulation Table

Standard value:
Inspection terminal

Voltage regulator ambient temperature _C

Voltage V

Terminal S

- 20

14.2 - 15.4

20

13.9 - 14.9

60

13.4 - 14.6

80

13.1 - 14.5

16-9

ENGINE ELECTRICAL - Charging System

Special
patterns
pickup

Alternator

Analyzer

WAVEFORM CHECK USING AN ANALYZER

MEASUREMENT METHOD
Connect the analyzer special patterns pick-up to the alternator
B terminal.

B terminal

STANDARD WAVEFORM
Observation Conditions
FUNCTION

SPECIAL PATTERNS

PATTERN HEIGHT

VARIABLE

VARIABLE knob

Adjust while viewing the waveform.

PATTERN SELECTOR

RASTER

Engine speed

Curb idle speed

0.4
0.2
Voltage at
alternator
B terminal

0
- 0.2
- 0.4

Time

NOTE
The voltage waveform of the alternator B terminal can undulate
as shown at left. This waveform is produced when the regulator
operates according to fluctuations in the alternator load
(current), and is normal for the alternator.
In addition, when the voltage waveform reaches an
excessively high value (approx. 2 V or higher at idle), it often
indicates an open circuit due to a brown fuse between
alternator B terminal and battery, but not a defective alternator.

16-10

ENGINE ELECTRICAL - Charging System

EXAMPLES OF ABNORMAL WAVEFORMS

NOTE
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob
on the analyzer.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not
operating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.
Abnormal waveforms

Problem
cause

Abnormal waveforms

Problem
cause

Example 1

Open
diode

Example 4

Short in
stator coil

Example 2

Short in
diode

Example 5

Open
supplementary
diode

Example 3

Broken
wire in
stator coil

At this time, the charging warning lamp

is illuminated.

Alternator relay

ALTERNATOR RELAY CONTINUITY CHECK

1. Remove the alternator relay from the relay box inside
the engine compartment.
2. Set the analogue-type circuit tester to the W range and
check that there is continuity when the (+) terminal of
the tester is connected to terminal 2 of the alternator
relay and the ( - ) terminal is connected to terminal 4.
3. Next, check that there is no continuity when the (+) terminal
is connected to terminal 4 and the ( - ) terminal is connected
to terminal 2.
4. If defect is found in steps 2 and 3 above, replace the
alternator relay.

ENGINE ELECTRICAL - Charging System

ALTERNATOR

16-11
16100140286

REMOVAL AND INSTALLATION

Pre-removal Operation
Under Cover and Side Cover (R.H. side) Removal

Post-installation Operation
D Drive Belt Tension Adjustment
(Refer to GROUP 11 - On-vehicle Service.)
D Under Cover and Side Cover (R.H. side) Installation

<4G6>

20 - 25 Nm

1
2

24 Nm

4
49 Nm

<4G9>
20 - 25 Nm

49 Nm

4
44 Nm

Removal steps
1. Drive belt (Power steering, A/C)
2. Drive belt (Alternator)
3. Alternator connector

4. Alternator
5. Alternator brace

16-12

ENGINE ELECTRICAL - Charging System

DISASSEMBLY AND REASSEMBLY

1
4

5
7

12
10
9
8

14
13
11

AA"
AB"

Disassembly steps
1. Front bracket assembly
2. Alternator pulley
AB" 3. Rotor
4. Rear bearing
5. Bearing retainer
6. Front bearing
7. Front bracket

AC"

8.
9.
AC" "AA 10.
11.
12.
13.
14.

Startor
Plate
Regulator assembly
Brush
Slinger
Rectifier
Rear bracket

ENGINE ELECTRICAL - Charging System

16-13

DISASSEMBLY SERVICE POINTS

AA" FRONT BRACKET ASSEMBLY REMOVAL
Insert flat tip screwdrivers or the like in the clearance between
the front bracket assembly and stator core, to pry open and
separate the stator and front bracket.
Caution
Do not insert the screwdriver too far, or the stator coil
gets damaged.

AB" ALTERNATOR PULLEY REMOVAL

Face the pulley side upward, fix the rotor with a work bench
and remove the pulley.
Caution
Use care not to damage the rotor.

Soldered

AC" STATOR/REGULATOR ASSEMBLY REMOVAL

1. Unsolder the stator with a soldering iron (180 to 250W).
Complete this work within four seconds not to transfer
heat to the diode.
2. When removing the rectifier from the regulator assembly,
remove the soldered sections of the rectifier.
Caution
(1) Use care to make sure that the heat of the soldering
iron is not transmitted to the diodes for a long
period.
(2) Use care that no undue force is exerted to the
lead wires of the diodes.

16-14

ENGINE ELECTRICAL - Charging System

REASSEMBLY SERVICE POINTS
Wire

"AA REGULATOR ASSEMBLY INSTALLATION

After installing the regulator assembly, insert a wire into the
hole provided on the rear bracket while pressing in the brush
to fix the brush.
NOTE
The brush is fixed when a wire is inserted, making rotor
installation easier.

Rear bracket
Brush
Wire

Wire

"BA ROTOR INSTALLATION

After installing the rotor, remove the wire used to fix the brush.

INSPECTION

16100170216

ROTOR CHECK
1. Check the continuity between the rotor coil slip rings,
and replace the rotor if the resistance value is not at
the standard value.
Standard value: 3 - 5 W

2. Check the continuity between the slip ring and core, and
if there is continuity, replace the rotor.

ENGINE ELECTRICAL - Charging System

16-15

STATOR CHECK
1. Check the continuity between the coil leads, and if there
is continuity, replace the stator.

2. Check the continuity between the coil and core, and if

there is continuity, replace the stator.

RECTIFIER CHECK
1. Inspect the (+) heat sink by checking the continuity
between the (+) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.

2. Inspect the ( - ) heat sink by checking the continuity

between the ( - ) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.

3. Check the diode trio by connecting an ohmmeter to both

ends of each diode and check the continuity of the three
diodes.
If there is a continuity at both ends, or if there is no
continuity, the diode is damaged so replace the rectifier.

16-16

ENGINE ELECTRICAL - Charging System

BRUSH CHECK
1. Measure the length of the brush protrusion shown in the
illustration, and replace the brush if the measured value
is below the limit value.
Limit: 2 mm or less

Protrusion
length

Soldered

2. The brush can be removed if the solder of the brush

lead wire is removed.
3. When installing a new brush, insert the brush into the
holder as shown in the illustration, and then solder the
lead wires.

16-17

ENGINE ELECTRICAL - Starting System

STARTING SYSTEM
GENERAL INFORMATION
If the ignition switch is turned to the START
position, current flows in the pull-in and holding
coils provided inside magnetic switch, attracting
the plunger. When the plunger is attracted, the
lever connected to the plunger is actuated to
engage the starter clutch.
On the other hand, attracting the plunger will turn
on the magnetic switch, allowing the B terminal

and M terminal to conduct. Thus, current flows to

engage the starter motor.
When the ignition switch is returned to the ON
position after starting the engine, the starter clutch
is disengaged from the ring gear.
An overrunning clutch is provided between the
pinion and the armature shaft, to prevent damage
to the starter.

SYSTEM DIAGRAM
Pull-in coil

Holding coil Plunger

Lever
Over-running
clutch
Pinion shaft

Ignition
switch
Armature
Battery

Brush

Yoke

STARTER MOTOR SPECIFICATIONS

Items

4G9

4G6

Type

Reduction drive with planetary gear

Reduction drive with planetary gear

Rated output kW/V

1.2/12

1.4/12

No. of pinion teeth

SERVICE SPECIFICATIONS
Items

Standard value

Limit

Pinion gap mm

0.5 - 2.0

Commutator outer diameter mm

29.4

28.8

Commutator runout mm

0.05

0.1

Commutator undercut mm

0.5

0.2

16-18

ENGINE ELECTRICAL - Starting System

STARTER MOTOR

Switch

<4G9>

INSPECTION

S
B

PINION GAP ADJUSTMENT

1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12V battery between S-terminal and
M-terminal.
3. Set switch to ON, and pinion will move out.

Battery

Wire

<4G6>

Caution
This test must be performed quickly (in less than
10 seconds) to prevent coil from burning.

Switch
S

Battery

Wire

4. Check pinion to stopper clearance (pinion gap) with a

thickness gauge.
Pinion gap: 0.5 - 2.0 mm

Stopper
Pinion gap
Pinion

5. If pinion gap is out of specification, adjust by adding or

removing gaskets between magnetic switch and front
bracket.

ENGINE ELECTRICAL - Starting System

<4G9>
S
M

Battery

16-19

MAGNETIC SWITCH PULL-IN TEST

1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12V battery between S-terminal and
M-terminal.
Caution
This test must be performed quickly (in less than
10 seconds) to prevent coil from burning.

Wire

3. If pinion moves out, then pull-in coil is good. If it doesnt,

replace magnetic switch.
<4G6>
S
Battery

Wire

<4G9>
S
Battery

Wire

MAGNETIC SWITCH HOLD-IN TEST

1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12V battery between S-terminal and body.
Caution
This test must be performed quickly (in less than
10 seconds) to prevent coil from burning.
3. Manually pull out the pinion as far as the pinion stopper
position.
4. If pinion remains out, everything is in order. If pinion moves
in, hold-in circuit is open. Replace magnetic switch.

<4G6>
S
Battery

Wire

16-20

ENGINE ELECTRICAL - Starting System

<4G9>

Carbon-pile rheostat

Ammeter

Starter
motor

Battery

V
Voltmeter

Carbon-pile rheostat

<4G6>
S

Ammeter

Battery
Starter
motor

Voltmeter

<4G9>

Battery

Wire

FREE RUNNING TEST

1. Place starter motor in a vise equipped with soft jaws
and connect a fully-charged 12-volt battery to starter motor
as follows:
2. Connect a test ammeter (100-ampere scale) and carbon
pile rheostat in series with battery positive post and starter
motor terminal.
3. Connect a voltmeter (15-volt scale) across starter motor.
4. Rotate carbon pile to full-resistance position.

5. Connect battery cable from battery negative post to starter

motor body.
6. Adjust the rheostat until the battery voltage shown by
the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns smoothly
and freely.
Current: max. 90 Amps

MAGNETIC SWITCH RETURN TEST

1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12V battery between M-terminal and body.
Caution
This test must be performed quickly (in less than
10 seconds) to prevent coil from burning.
3. Pull pinion out and release. If pinion quickly returns to
its original position, everything is in order. If it doesnt,
replace magnetic switch.
Caution
Be careful not to get your fingers caught when pulling
out the pinion.

<4G6>

Battery

Wire

16-21

ENGINE ELECTRICAL - Starting System

DISASSEMBLY AND REASSEMBLY
2

13
16

14

12

11

15
21

18

19

20
3

17

22

7
6
9

10

AA"

AB"
AB"

Disassembly steps
1. Screw
2. Magnetic switch
3. Screw
4. Through bolt
5. Rear bracket
6. Brush holder
7. Brush
8. Rear bearing
9. Armature
10. Yoke assembly
11. Ball

12.
13.
14.
15.
16.
AC" "AA 17.
AC" "AA 18.
19.
20.
21.
22.

Packing A
Packing B
Plate
Planetary gear
Lever
Snap ring
Stop ring
Overrunning clutch
Internal gear
Planetary gear holder
Front bracket

16-22
Magnetic
switch

ENGINE ELECTRICAL - Starting System

S terminal
M terminal

DISASSEMBLY SERVICE POINTS

AA" MAGNETIC SWITCH REMOVAL
Disconnect the field coil wire from terminal M of the
magnetic switch.

Field coil
wire

AB" ARMATURE AND BALL REMOVAL

When removing the armature, do not lose the ball placed
at the end as a bearing.

Socket
Stop ring

AC" SNAP RING/STOP RING REMOVAL

1. Using an appropriate wrench socket, push the stop ring
toward the overrunning clutch.

Pinion gear
Overrunning
clutch

Snap ring

Snap ring pliers

2. Remove the snap ring with snap ring pliers and then
remove the stop ring and overrunning clutch.

Pinion gear
Overrunning
clutch

STARTER MOTOR PARTS CLEANING

1. Do not immerse the parts in cleaning solvent. Immersing
the yoke and field coil assembly and/or armature will
damage insulation. Wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent. The
overrunning clutch is pre-lubricated at the factory and
solvent will wash lubrication from clutch.
3. The drive unit may be cleaned with a brush moistened
with cleaning solvent and wiped dry with a cloth.

ENGINE ELECTRICAL - Starting System

16-23

REASSEMBLY SERVICE POINTS

"AA STOP RING/SNAP RING INSTALLATION
Using an appropriate tool, pull the stop ring over the snap
ring.
Stop ring
Stop ring

Overrunning
clutch
Snap ring

INSPECTION
COMMUTATOR
1. Place the armature in a pair of V blocks and check
the runout with a dial indicator.
Standard value: 0.05 mm
Limit: 0.1 mm

2. Measure the commutator outer diameter.

Standard value: 29.4 mm
Limit: 28.8 mm

3. Check the undercut depth between segments.

Undercut
Segment

Mica

Free
Lock

Standard value: 0.5 mm

Limit: 0.2 mm

OVERRUNNING CLUTCH
1. Check that the pinion locks when it is turned
counterclockwise and moves smoothly when it is turned
clockwise.
2. Check the pinion for wear or damage.

16-24

ENGINE ELECTRICAL - Starting System

BRUSH
1. Check the brush for roughness of the surface that contacts
the commutator and check the brush length.

Wear limit line

Growler

Limit: Wear limit line

2. In case the contacting surface has been corrected or
the brush has been replaced, correct the contacting
surface by winding sandpaper around the commutator.

ARMATURE COIL SHORT-CIRCUIT TEST

1. Place armature in a growler.
2. Hold a thin steel blade parallel and just above while rotating
armature slowly in growler. A shorted armature will cause
blade to vibrate and be attracted to the core. Replace
shorted armature.
Caution
Clean the armature
checking.

surface

thoroughly before

3. Check the insulation between each commutator segment

and armature coil core.
If there is no continuity, the insulation is in order.

ARMATURE COIL OPEN-CIRCUIT INSPECTION

Check the continuity between segments. If there is continuity,
the coil is in order.

16-25

ENGINE ELECTRICAL - Ignition System

IGNITION SYSTEM
GENERAL INFORMATION
This system is equipped with four ignition coils with
built-in power transistors for each of the cylinders.
Interruption of the primary current flowing in the
primary side of an ignition coil generates a high
voltage in the secondary side of the ignition coil.
The high voltage thus generated is applied to the
spark plugs to generate sparks.
The engine-ECU turns the power transistors inside
the ignition coils alternately on and off. This causes
the primary currents in the ignition coils to be
alternately interrupted and allowed to flow to fire
the cylinders in the order 1 - 3 - 4 - 2.

The engine-ECU determines which ignition coil

should be controlled by means of the signals from
the camshaft position sensor and the crank angle
sensor. It also detects the crankshaft position, in
order to provide ignition at the most appropriate
timing in response to the engine operation
conditions.
When the engine is cold or running at high altitudes,
the ignition timing is slightly advanced to provide
optimum performance. Furthermore, if knocking
occurs, the ignition timing is gradually retarded until
knocking ceases.

SYSTEM DIAGRAM
Ignition switch

Air flow sensor

Battery

Barometric pressure sensor

Intake air temperature sensor
Engine coolant temperature
sensor
Accelerator pedal position
switch <4G6>

EngineECU

Camshaft position sensor

Crank angle sensor

Ignition coil

Ignition switch-ST
Detonation sensor
Vehicle speed sensor
Inhibitor switch <A/T>

Spark plug

To tachometer

Cylinder No.

IGNITION COIL SPECIFICATION

Items

Specification

Type

Molded 4-coil

SPARK PLUG SPECIFICATION

Items

4G6

4G9

NGK

IZFR5B

IZFR6B

16-26

ENGINE ELECTRICAL - Ignition System

SERVICE SPECIFICATIONS
SPARK PLUG
Items

Standard value

Limit

Spark plug gap mm

0.5 - 0.6

0.75

Spark plug insulation resistance MW

ON-VEHICLE SERVICE
+
-

1.5 V

IGNITION COIL (WITH BUILT-IN POWER

TRANSISTOR) CHECK
PRIMARY COIL AND POWER TRANSISTOR
CONTINUITY CHECK
NOTE
1. An analogue-type circuit tester should be used.
2. Connect the negative ( - ) prove of the circuit tester to
terminal 1.
Caution
This test must be performed quickly (in less than 10
seconds) to prevent coil from burning and power
transistor from breakage.
Voltage: 1.5V

Terminal No.
1

When current is
flowing
When current is
not flowing

SECONDARY COIL CHECK

NOTE
It is impossible to check the secondary coil through the
continuity check as a diode is integrated in the secondary
coil circuit of this ignition coil. So, check the secondary coil
in the following procedure.
1. Disconnect the ignition coil connector.
2. Remove the ignition coil and install a new spark plug
to the ignition coil.
3. Connect the ignition coil connector.
4. Earth the side electrode of the spark plug and crank
the engine.

ENGINE ELECTRICAL - Ignition System

16-27

5. Check that spark is produced between the electrodes of

the spark plug.
6. If no spark is produced, replace the ignition coil with a
new one and recheck.
7. If spark is produced with the new ignition coil, replace
the old one as it is faulty. If no spark is produced again,
the ignition circuit is suspected as faulty. Check the ignition
circuit.

SPARK PLUG CHECK AND CLEANING

Caution
1. The spark plug gap for iridium plugs should not be
adjusted.
2. Cleaning iridium plugs may result in damage to the
iridium tip. Therefore, if cleaning is necessary
because the plug is sooty, use a plug cleaner, and
do not clean the plug for more than 20 seconds in
order to preserve the electrodes. A wire brush should
never be used.
3. The spark plugs in GDI engines are special iridium
plugs in which the electrodes can become black even
when the plugs are working normally. Carbon which
may become deposited on these plugs burns off more
readily than with conventional plugs, and so should
not cause any problems with spark plug performance.
Judgement of whether a spark plug is operating
normally or not should be made by checking the
insulation resistance.

1. Remove the ignition coils.

2. Remove the spark plugs.
3. Check the spark plug gap. Replace the spark plug if the
gap exceeds the limit.
Limit: 0.75 mm
Standard value: 0.5 - 0.6 mm
4. Measure the spark plug insulation resistance. Replace
the spark plug if the measured value is lower than the
limit value.
Limit: 1 MW
5. Clean the spark plug holes.
6. Install the spark plugs.
7. Install the ignition coils.

16-28

ENGINE ELECTRICAL - Ignition System

CAMSHAFT POSITION SENSOR CHECK
Refer to GROUP 13A - Troubleshooting <4G6> or GROUP
13B - Troubleshooting <4G9>.

CRANK ANGLE SENSOR CHECK

Refer to GROUP 13A - Troubleshooting <4G6> or GROUP
13B - Troubleshooting <4G9>.

DETONATION SENSOR CHECK

Check the detonation sensor circuit if self-diagnosis code,
No. 31 is shown.
NOTE
For information concerning the self-diagnosis codes, refer
to GROUP 13A - Troubleshooting <4G6> or GROUP 13B
- Troubleshooting <4G9>.

ENGINE ELECTRICAL - Ignition System

IGNITION COIL

16-29
16300320174

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation
Engine Cover Removal and Installation

10 Nm

1
3
25 Nm

Removal steps
1. Ignition coil connector
2. Ignition coil
3. Spark plug

CRANK ANGLE SENSOR

16300350036

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation
D Timing Belt Removal and Installation <4G6>
(Refer to GROUP 11A.)

<4G6>
10 - 12 Nm

Crank angle sensor

9 Nm

Timing Belt Front Lower Cover Removal and

Installation <4G9> (Refer to GROUP 11B.)

<4G9>
10 - 12 Nm

Crank angle sensor

9 Nm

16-30

ENGINE ELECTRICAL - Ignition System

CAMSHAFT POSITION SENSOR

16300340026

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation
Engine Cover Removal and Installation

<4G6>

9 Nm

Camshaft position sensor

<4G9>
9 Nm

Camshaft position sensor

16-31

ENGINE ELECTRICAL - Ignition System

DETONATION SENSOR

16300280144

REMOVAL AND INSTALLATION

Caution
Do not subject the detonation sensor to any shocks.
Pre-removal and Post-installation Operation
D Engine Cover Removal and Installation
D Air Cleaner Assembly Removal and Installation

Intake Manifold Stay Removal and Installation

(Refer to GROUP 15.)

<4G6>

1
20 - 25 Nm

<4G9>

10 - 12 Nm

1
20 - 25 Nm

AA" "AA 1. Detonation sensor

REMOVAL SERVICE POINT

AA" DETONATION SENSOR REMOVAL

INSTALLATION SERVICE POINT

"AA DETONATION SENSOR INSTALLATION
MD998773

NOTES